52 Int. J. Powertrains, Vol. 3, No. 1, 2014 Copyright © 2014 Inderscience Enterprises Ltd. Model-based development and calibration of last generation diesel powertrains for passenger cars Fabio Mallamo*, Federico Millo and Luciano Rolando Energy Department (DENERG), Politecnico di Torino, Corso Duca degli Abruzzi, 24, 10129 Torino, Italy E-mail: fabio.mallamo@polito.it E-mail: federico.millo@polito.it E-mail: luciano.rolando@polito.it *Corresponding author Abstract: This paper presents an original model-based approach to the system level development and calibration of diesel powertrains for passenger cars, implemented in a comprehensive software tool. The models for the different subsystems are coupled to execute optimisation loops, involving also the system calibration, and are characterised by flexibility of usage, limited tuning effort and reduced computational time. As an example of the general approach, the engine model is described and some results from its execution are shown and compared with the measurements. Finally, a practical example is given of the usage of the tool for system level optimisation through a specifically developed methodology. Keywords: model-based; development and calibration; system optimisation; diesel powertrain; feasibility assessment. Reference to this paper should be made as follows: Mallamo, F., Millo, F. and Rolando, L. (2014) ‘Model-based development and calibration of last generation diesel powertrains for passenger cars’, Int. J. Powertrains, Vol. 3, No. 1, pp.52–74. Biographical notes: Fabio Mallamo is an Assistant Professor at the Politecnico di Torino, where he received his PhD in Energetics in 2004 with a thesis on the optimisation of fuel consumption and emissions of common rail diesel engines. He has been working since 2001 in the automotive field, both at research and application. From 2005 to 2011 he has been responsible at General Motors Powertrain Europe for the system development and calibration of diesel engines for different markets. The main target of his activity is the optimisation of the general performance of the automotive powertrains, focusing on the trade-off between emissions and fuel economy. Federico Millo was appointed as an Associate Professor of Internal Combustion Engines in 1998 at the Politecnico di Torino. His research activity has been focused on internal combustion engines, in particular on the analysis and on the diagnostic of the combustion process, on alternative fuels, on pollutant emission control in S.I. and diesel engines, on engine modelling and on the development of engine control strategies for conventional as well as for hybrid powertrains. He has been responsible and principal investigator for several research projects with major industrial companies and with public institutions.